Compressor (For 2Tr-Fe) Installation

When replacing the compressor and magnet clutch with a new one, gradually discharge the refrigerant gas from the service valve and drain the following amount of oil from the new compressor and magnet clutch before installation.

Standard:

for Single Air Conditioning System:

(The amount of oil inside a new cooler compressor: 120 to 135 cc (4.1 to 4.6 fl. oz.)) - (The amount of oil remaining in the removed cooler compressor) = (The amount of oil to be removed when replacing the compressor)

Standard:

for Dual Air Conditioning System:
(The amount of oil inside a new cooler compressor: 180 to 195 cc (6.1 to 6.6 fl. oz.)) - (The amount of oil remaining in the removed cooler compressor) = (The amount of oil to be removed when replacing the compressor)

NOTICE:

1. When checking the compressor oil level, follow the A/C system precautions.
   
2. Since compressor oil remains in the pipes of the vehicle, if a new compressor is installed without removing some oil from the compressor, the oil amount becomes excessive. Excessive oil prevents heat exchange in the refrigerant cycle and causes refrigeration system failure.
   
3. If the volume of oil remaining in the removed compressor and magnet clutch is small, check for oil leakage.
   
4. Be sure to use ND-OIL 8 or equivalent compressor oil.
   

Install the compressor with the 4 bolts and tighten the bolts in the order shown in the illustration.

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Connect the connector.

Remove the vinyl tape attached to the hose.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor.

Compressor oil:

ND-OIL 8 or equivalent

Install the O-ring to the suction hose.

Connect the suction hose with the bolt.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Remove the vinyl tape attached to the hose.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor.

Compressor oil:

ND-OIL 8 or equivalent

Install the O-ring to the discharge hose.

Connect the discharge hose with the bolt.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Connect the vane pump assembly with the 2 bolts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Connect the 2 connectors.

Install the pressure feed tube with the bolt.

Torque:

28 N*m{285 kgf*cm, 21 ft.*lbf}

Install the fan pulley to the engine water pump assembly.

Place the shroud together with the coupling fan between the radiator assembly and engine.

NOTICE:

Be careful not to damage the radiator core.

Temporarily install the fluid coupling fan to the engine water pump assembly with the 4 nuts. Tighten the nuts as much as possible by hand.

Attach the claws of the shroud to the radiator assembly as shown in the illustration.

Install the fan shroud with the 2 bolts.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Install the fan and generator V-belt (LandCruiser RM000000YMN02UX.html).

Tighten the 4 nuts of the fluid coupling fan.

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Attach the claw to close the flexible hose clamp as shown in the illustration.

Connect the No. 2 radiator hose to the radiator assembly, and slide the hose clamp to secure the hose.

HINT:

Make sure the direction of the hose clamp is as shown in the illustration.

Connect the No. 1 radiator hose to the radiator assembly, and slide the hose clamp to secure the hose.

HINT:

Make sure the direction of the hose clamp is as shown in the illustration.

Install the radiator reservoir with the 3 bolts.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Connect the reservoir hose to the radiator assembly.

Install the fan and generator V belt to all the pulleys except the tensioner pulley.

Use the hexagonal part indicated by the arrow in the illustration to move the tensioner pulley downward and install the fan and generator V belt to the tensioner pulley.

NOTICE:

1. The backside of the fan and generator V belt should face the tensioner pulley.
   
2. Check that the fan and generator V belt is properly set on each pulley.
   

Hook the No. 1 engine under cover sub-assembly to the vehicle body as shown in the illustration.

Install the 4 bolts.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Install the front bumper lower cover with the 5 bolts.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

Install the clip.

Perform vacuum purging using a vacuum pump.

Charge refrigerant HFC-134a (R134a).

NOTICE:

1. Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
   
2. Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.
   

Tighten the cylinder block drain cock plug.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}

Tighten the radiator drain cock plug by hand.

Disconnect the 2 vinyl hoses.

Add engine coolant.

Standard Capacity:

Item		Specified Condition
for Automatic Transmission	w/o Rear Heater	8.1 liters (8.6 US qts, 7.1 Imp. qts)
	w/ Rear Heater	9.9 liters (10.5 US qts, 8.7 Imp. qts)
for Manual Transmission	w/o Rear Heater	8.3 liters (8.8 US qts, 7.3 Imp. qts)
	w/ Rear Heater	10.1 liters (10.7 US qts, 8.9 Imp. qts)

NOTICE:

Do not substitute plain water for engine coolant.

HINT:

1. TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
   
2. Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the coolant level. If the coolant level is low, add coolant.
   

Slowly pour coolant into the radiator reservoir until it reaches the F line.

Install the reservoir cap.

Install the radiator cap sub-assembly.*1

Start the engine and stop it immediately.*2

Allow approximately 10 seconds to pass. Then remove the radiator cap sub-assembly and check the coolant level. If the coolant level has decreased, add coolant.*3

Repeat steps *1, *2 and *3 until the coolant level does not decrease.

HINT:

Be sure to perform this step while the engine is cold, as air in the No. 1 radiator hose will flow into the radiator if the engine is warmed up and the thermostat opens.

Install the radiator cap sub-assembly.*4

Set the air conditioning as follows.*5

Start the engine, warm it up until the thermostat opens, and then continue to run the engine for several minutes to circulate the coolant.*6

CAUTION:

1. Wear protective gloves. Hot areas on the parts may injure your hands.
   
2. Be careful of the fan.
   
3. Be careful as the engine, radiator and radiator hoses are hot and can cause burns.
   

NOTICE:

1. Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the F line.
   
2. Do not start the engine when there is no coolant in the radiator reservoir.
   
3. Pay attention to the needle of the engine coolant temperature receiver gauge. Make sure that the needle does not show an abnormally high temperature.
   
4. If there is not enough coolant, the engine may burn out or overheat.
   

HINT:

1. Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air while warming up the engine.
   
2. The thermostat opening timing can be confirmed by pressing the No. 2 radiator hose by hand and checking when the engine coolant starts to flow inside the hose.
   

Stop the engine, wait until the engine coolant cools down to ambient temperature. Then remove the radiator cap sub-assembly and check the coolant level.*7

CAUTION:

Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

If the coolant level has decreased, add coolant and warm up the engine until the thermostat opens.*8

If the coolant level has not decreased, check that the coolant level in the radiator reservoir is at the F line.
If the coolant level is below the F line, repeat steps *4 through *8.
If the coolant level is above the F line, drain coolant until the coolant level reaches the F line.

Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.

NOTICE:

Be sure to warm up the compressor when turning the A/C switch is on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

Perform the operation under these conditions:

1. Stop the engine.
   
2. Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).
   
3. Repeat the test 2 or 3 times.
   
4. Make sure that some refrigerant remains in the refrigeration system. When compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm², 57 to 85 psi).
   

Using a halogen leak detector, check the refrigerant line for leakage.

If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.

Disconnect the connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.

Install the upper radiator support seal with the 13 clips.